Method of producing crimped continuous filament yarn



ug- 27 1963 A. J. RosENsTElN ETAL 3,101,521

METHOD oF PRonucING CRIMPED coNTINUous FILAMENT YARN Filed June 25, 1959 5 SheetS-Sheeil l FIC-7; 1 10 101010010100101MMoww l BY @j A TTORNE YS.

11g 27, 1963 Al J'. RosENsTElN "ETAL l 3,101,521

METHOD oF PRopucING CRIMPED CONTINUOUS FILAMENTYARN Filed June 25, 1959 5 Sheets-Sheet 2 BY ga/p' ATTO EYS.

ug- 127, 1963A A..J-RovsENs1-E|N ETAL. 3,101,521

METHOD OF' PRODUCING CRIMPED CONTINUOUS FILAMENT YARN Filed June 25. 1959 I 3 Sheets-Sheet 3 IN VENT ORS A TTO EY 3,lt)l,521 METHD @F PRDUCHNG C E .r CONTINUUUS FILAMENT YARN y Abraham J. Rosenstein, New Marlboro, Mass., Nathan Rosenstein, West Hartford, Conn., and Thomas F.

Suggs, Gastonia, NI., assigner-s to Spunize Co. of

America, Inc., Unionville, Conn., a corporation of Connecticut Filed June 2S, 1959, Ser. No. 822,837 l Claims. (Cl. 2S-72) This invention relates to an apparatus and method for producing crimped continuous iilament yarn (monoor multi-lament) and particularly relates to the production of crimped continuous iilament yarn having zig-zag multiplanar or uni-planar crimps which are arranged at a relatively low crimp angle. More speciiically, this invention relates to an apparatus and method for producing crimped continuous filament yarn wherein the filaments of the yarn are crimped at an angle of about 1809 and are then drawn out to a controllably limited degree in order to produce a product which retains a lower degree of crimp so as to atford greater dimensional stability.

In the patent to Rosenstein et al., No. 2,719,309, there `is disclosed a method of making crimped continuous filament yarn wherein a continuous `resin iilament yarn isA fed between smooth rolls into a crimpingtchamber having a restricted exit. The rotataion of thefrolls feeds the continuous iilament yarn into the chamber, folding the yarn over upon itself producing a series of crimps wherein the yarn is crimped at an angle of approximately 180 to its longitudinal axis.

Heretofore, in practicing the invention of the aforementioned Rosenstein et al. Patent No. 2,719,309, the yarn produced by the crimper was desirably subjected to heat after it emerged from the crimper, thereby setting the crimp. The heat setting operation was found to have many advantages, among which was the high crimp retention of the product, which gave it a very substantial amount of bulk and loftiness.

It has now been found that, for many purposes, it is desirable to produce a crimped continuous iilament yarn having a degree of crimp which is less than that produced in accordance with the aforementioned Rosenstein et al. patent, but having a degree of crimp which may be critically limited and controlled. Continuous filament yarn having a lesser but controlled degree of crimp is useful in and of itself, and is further useful in combination with highly crimped yarns of other types, or in combination with one or more other yarns.

Although the invention is highly advantageous for the `preparation of crimped synthetic polymer continuous filament yarns such as nylon, Dacron, Orlon, Acri1an, rayon, the cellulosic iibers and the like, it is similarly applicable to a wide variety of other synthetic libere.

It is accordingly an object of this invention to provide a novel apparatus and method for preparing crimped continuous 'filament yarn which has a lesser degree of crimp than the yarn produced in accordance with the Rosenstein et al. U.S. Patent No. 2,719,309, but which yarns have a controlled degree of crimp and greater dimensional stability.

Another object of this invention is to provide a method and apparatus for producing continuous iilament yarns having a very substantial number of crirnps per inch, but having a lesser degree of crimp than yarns which have been crimped in accordance with the aforementioned U.S. patent.

Still another object of this invention is to provide a l novel means for manufacturing a crimped continuous ilament yarn which has a series of zig-Zag crimps, all arranged at multi-plane angles to one another, wherein the 3 l d l ,dgl Patented Aug. 27, 1963 degree vof such crimp and the magnitude of such angle is substantially controlled.

Another object and advantage of this invention is to provide a crimped continuous filament yarn having a relatively 10W degree of crimp, which can be dyed more readily and efficiently.

`Other objects and advantages of this invention, including the simplicity and economy of the same and the ease with which the degree of crimp may be accurately controlled will further become apparent hereinafter and in the drawings whereof:

FIG. 1 is a view in side elevation, with parts shown in section, of an apparatus for producing crimped continuous filament yarn in accordance with one form of this invention.

FIG. 2 is an enlarged schematic view showing a relatively sharply crimped continuous ilament yarn produced in one stage of the process. y

FIG. 3 is a schematic view similar to FIG. 2, showing the crimped continuous lilament yarn after it has been subjected to a uniform tension.

FIG. 4 is a partial-plan view of the apparatus appearing in FIG. l, illustrating how the crimped web of yarn is drawn out in accordance With this invention.

FiG. 5 is a schematic View in side elevation showing an apparatus for combineddrawing-out and continuous dyeing of continuous filament yarn.

FIG. 6 is a View in side elevation, with parts shown in section, showing an alternate form of the invention and FIG. 7 is an enlarged view of a portion of the apparatus shown in FIG. 6.

` The specific forms of the invention shown in the drawings are not intended to dene or to limit the scope of the invention, and should be taken as illustrations of preferred forms thereof. Similarly, the rfollowing description relates to the specific forms of the invention as shown in the drawings, and does not limit the scope of the invention which is deiined in the appended claims.

Turning now to FIGS. l-3, the numbers liti, ll designate matching rollers, the axes of which are urged toward one another thereby forming a nip. A feeding device 12 is provided for feeding multiple continuous filament yarns Y into the nip between ,the rolls 1t), ll.

The number i3 designates a chamber which contines the yarn Y after it has passed between the rolls l0, l1. An exit door 14 is provided which is urged by the `spring l5 toward a table i6; This maintains the yarn Y compressed when it is within the chamber 13, thereby causing the yarns to bend upon themselves and to becrimped at an angle of substantially The internal pressure formed within the chamber 13 continuously forces the resulting crimped yarn out past the door llionto the table 16. At that location, the yarn has a rather high crimp such as the crimp appearing in FIG. 2.

The numbers 20, 21 designate further rolls which are urged against one another and which form a nip for the crimped yarn coming from the table ld. Spaced apart from the rolls 20, 2i is another set of rolls 22, 23, between which the fibers also pass. As will be apparent in FIG. 1, :a motor 24 operates throughV chains and sprockets to drive the rolls ll and 2i and also through a slip clutch 24M) to drive the roll 23. The gear ratios of the sprockets are such that the roll v23 is rotated at a greater peripheral velocity than the roll 2l, thereby causing a limited but controlled uniform tension to be applied to the iibers which are between theA rolls 2l land 23. This tension draws out the ibers l?,l producing a crimp of lesser angle, such as the crimp appearing in FIG. 3.

The rolls 22, 23 are preferably mounted on a slotted support so that they are adjustable toward and away from the rolls Z0, 21.

The product from rolls 22, 23 is led to any suitable device such as a quiller, twister, skeiner or coner, for example, or even a continuous dye machine as hereinafter described.

FIG. 4 shows how the limited degree of tension modiiies the crimped web to advantage. After crimping, the web consists of filaments that are interlocked, providing a mass (a) wherein the individual filaments are attached to adjacent laments. After limited tension has been applied, the individual filaments are separated as indicated at (b) in FIG. 4.

FIG. 5 shows a novel and advantageous apparatus and process wherein the web, crimped and drawn out as in FIG. 1, is passed directly from the rolls 22, 23 into a continuous dyeing machine generally designated 25. The details of the continuous dyeing machine are themselves not a part of this invention, and may be widely varied. The dyeing machine as shown has, for example, two dyeing sections 26, wherein the drawn-out filaments are concurrently dyed and heat-set, and two wash sections 28. Other treating sections may be used if desired. The drive 29 for the dyeing machine 2S is preferably interconnected with or at least driven in timed relation with the drive motor 24 of the crimper and the rolls 22, 23. Preferably `all the rolls of the dyeing machine, and the roll or rolls ahead of it, are dependently driven in order to avoid additional tensioning of the yarn. On the other hand, the rolls 22, 23 may themselves be incorporated into the dye bath so that the dye bath itself provides the tension to draw out the crimp.

Turning to FlGS. 6 and 7, table 16 has an extension 30 having a rounded end over which the crimped yarn continuously passes. Located at `a predetermined distance D beneath the end of the extension 30 is asubstantially horizontal plate 31 which is suspended from a pair of side bars 32 by means of cables 33, 33. The number 34 designates a container having slots 35, 35 through which portions of the plate 31 extend. Accordingly, the plate 31 has capacity to move up and down in the container 34. The cables 33, 33 are wound around a capstan 36 which is selectively reversibly driven from power source 24 through a change gear mechanism 37, in order to cause the plate 31. to move downwardly at a controlled speed that is related definitely to the bulk of the ber F, and both such factors are related in a manner to provide a yarn length which draws itself out by the action of gravity alone.

In operation, the apparatus of FIGS. 6 and 7 produces a highly crimped yarn as in PIG. 1, before it passes between rolls 2t? and 21, and the yarn utilizes its own weight in order to draw out the crimp by applying tension which is caused by gravity alone. The distance D in FIG. 6 is maintained substantially constant by the capstan 36 which gradually lowers the plate 31 as the container 34 is gradually tilled with crimped yarn. When the plate 31 is on the bottom of the container 34, the container itself is full of crimped yarn having a carefully controlled degree of crimp, at a much lesser crimp angle that the crimp angle of the bers produced at the crimping chamber itself. In order to remove the container full of crimped yarn, the entire container 34 together with the plate 31 at the bottom thereof is removed.

Preferably, the crimped continuous filament yarn as produced in accordance with FlGS. 1-4, 6 and 7 is subjected to a heat-setting operation for the purpose of retaining the residual crimp. The heat-setting may be accomplished in a variety ofV ways, as by subjecting the yarn continuously to infrared or other heat, or by heat-setting in batch style in a steam chest, or the like. However it is highly preferred in accordance with this invention to set the residual crimp by subjecting the yarn to a simultaneous dyeing and heat-setting operation, wherein hot aqueous dye is provided, and wherein the crimped yarn is maintained immersed in such hot dye for a predetermined period of time and at a heat-setting temperature.

The yarn may also be formed into a fabric before heatsetting, and then heat-set or dyed.

Accordingly it will be appreciated that continuous lilament yarn may be crimped utilizing the aforementioned Rosenstein crimping process, without any heat-setting, after which the crimped product is then intentionally drawn out or subjected to limited and controlled tension in order to provide a predetermined lesser degree of crimp. f

It is important to emphasize, however, that it is not necessary in every case to provide yan ultimate heat-setting step. The continuous iilament yarn, Without any heatsetting but after the crimp is partially drawn out, can be fabricated directly into a fabric or other material, either by itself or in combination with one or more other yarns. The continuous dyeing method ordinarily provides much less heat-setting than pressure dyeing at higher temperatures, for example, and either form may be used.

lt is important and advantageous that the degree of crimp retention is subject to continuous and accurate control throughout the crimping and drawing out process. The degree of crimp retention may be maintained at a substantially uniform value as the yarns or fibers pass continuously through the crimping and 4drawing out operation.

lt will be appreciated that the means for partially drawing out the crimp may be modified in a wide variety of ways, depending upon the extent to which the tension is to be limited, the nature of the crimped larnents and many other variables. For example, the rolls 22 and 23 could be replaced by a single drum with the crimped web wound spirallyaround it and with the drum controllably rotated or even idled in order to provide a very small tension ywhich greatly limits the extent to which the crimp is drawn out.

The products which result from the proces of this invention may readily be utilized for the production of textile fabrics, by knitting, weaving and other fabricating operations, or even by the formation of non-woven textiles. They may be used alone or in combination with other yarns for the production of a wide variety of textile fabrics including hosiery, sweaters, rugs, carpets and the like.

Although this invention has been described with reference -to specific forms and embodiments, it will be appreciated that many changes may be made Without depanting from the scope of the invention. For example, equivalent elements and method steps may be substituted for those specifically described, parts and method steps may be reversed, and certain features may be used independently of other features, all without departing from the spirit or scope of this invention as defined in the appended claims.

Having thus described our invention, we claim:

1. `In a method of forming crimped continuous lilament yarn, the steps which comprise crimping at least one filament of said yarn without heat-setting at an angle of approximately to the longitudinal axis of said filament, and thereafter subjecting the crimped yarn to a controlled degree of tension, thereby partially drawing out the cnimp initially produced while retaining a predetermined crimp in the yarn of substantially uniform value.

2. The method defined in claim 1, wherein said yarn is monoiilament yarn.

3. Fllhe method detined in claim 1, wherein said yarn is multililament yarn.

4. The method deiined in claim 1, wherein the tension is applied continuously to the yarn While said yarn is moving, by drawing off the yarn at dilferent speeds at spaced-apart locations.

5. The method defined -in claim 1, wherein the tension is applied by gravity.

6. The method defined in claim 5, wherein the tension is applied by continuously extending vertically downwardly a predetermined substantially constant length of the yarn produced in the crimping step, thereby drawing out the crimp under a substantially constant tension.

7. In a method for forming crimped continuous lament yarn, the steps which comprise bending at least one of said laments through an angle of approximately 180 and exerting pressure on said filament while so bent, thereby cn'mpzingsaid iilament Without heat-setting, and thereafter, subjecting the crimped yarn to a controlled degree of tension, thereby partially drawing out crimp initially produced which retaining a predetermined crimp in the yarn of substantially uniform Value.

8. in a method of forming crimped continuous iilament yarn, the steps which comprise bending said yarn through an angle of approximately 180 and exerting pressure on said yarn while so bent, thereby crimping said yarn without heat-setting, therefater subjecting -the crimped yarn to a controlled degree of tension, thereby partially drawing out the crdmp initially produced While retaining a predetermined crimp in fthe yarn of substantially uniform value, and then immersing the resulting yarn in a hot aqueous dye solution maintained at a temperature suicient to lheat-set said yarn.

9. In a method of forming crimped continuous filament yarn, the steps which comprise bending a plurality of said yarns through an angle of approximately 180 to the longitudinal taxis thereof without `heat-setting, thereby forming `a weblike mass of yarns, thereafter subjecting Said crimped yarn to a controlled degree of tension, thereby separating said yarns and partially drawing out the crimp initially produced .therein While retaining a predetermined crimp in the yarn of substantiallly uniform value.

10. The method dened in claim 9 wherein is included a further step of immersing the resulting yarn in a hot aqueous dye solution maintained at a temperature sufficient to heat-set said yarn.

References Cited in the le of this patent UNITED STATES PATENTS 2,575,838 Rainard Nov. 20, 1951 2,636,250 Hemmi Apr. 28, 1953 2,647,285 Pfau Aug. 4, 1953 2,669,001 Keen Feb. 16, 1954 2,696,034 Swartz Dec. 7, 1954 2,760,252 Shattuck Aug. 28, 1956 2,854,701 Rainard Oct. 7, 1958 2,917,784 Spence et al. Dec. 22, 1959 2,917,806 Spence et al. Dec. 22, 1959 FOREIGN PATENTS 563,224 Belgium Dec. 31, 1957 837,573 Great `Britain June 15, 1960 

1. IN A METHOD OF FORMING CRIMPED CONTINUOUS FILAMENT YARN, THE STEPS WHICH COMPRISE CRIMPING AT LEAST ONE FILAMENT OF SAID YARN WITHOUT HEAT-SETTING AT AN ANGLE OF APPROXIMATELY 180* TO THE LONGITUDINAL AXIS OF SAID FILAMENT, AND THEREAFTER SUBJECTING THE CRIMPED YARN TO A COINTROLLED DEGREE OF TENSION, THEREBY PARTIALLY DRAWING OUT THE CRIMP INITIALLY PRODUCED WHILE RETAINING A PREDETERMINED CRIMP IN THE YARN OF SUBSTANTIALLY UNIFORM VALUE. 